Advanced Gas-Heated Reformer: P. W. Farneil
Advanced Gas-Heated Reformer: P. W. Farneil
Based upon extensive experience in the design and operation of certain Gas-Heated Reformers
(GHRs), a modified design of the GHR known as the Advanced GHR has been developed. The AGHR
has been based upon the successful features of the GHR, as proven over the past 10 years with the
introduction of several new features that offer improved benefits to the operator of the novel
technology over conventional technology. After more than one year of successful operation, the
AGHR is viewed as being commercially proven.
P. W. Farneil
Synetix, Billingham, England
I
n 1988 ICI commissioned two Leading Concept
Ammonia plants at its Sevemside site in England. power and steam requirements are met. The reformer
This was followed in 1994 when BHP Petroleum used in these LCA and LCM plants is a compact
commissioned its Methanol Research Plant using reformer similar to a shell-and-tube heat exchanger,
Synetix's Leading Concept Methanol process near known as the Gas Heated Reformer (GHR). To date,
Melbourne, Australia. The most recent plant utilizing ICI has presented several technical papers on the GHR
Synetix's novel reforming technology is the LCA plant itself, and the LCA and LCM processes (Elkins et al,
operated by Mississippi Chemicals in Yazoo City, MS. 1991; Armitage et al., 1992; Farnell, 1996).
The original LCA plants were the first real significant During the operation of the current LCA and LCM
change in both ammonia and methanol process tech- plants, and also during design studies for world-scale
nology since the introduction of the large single plants, a revised design of the GHR has been devel-
stream, energy integrated designs of the 1960s. Both oped which is known as the Advanced Gas Heated
of the plants incorporate many innovative features in Reformer (AGHR). The design of the AGHR has
their process design, catalytic reactor design, and con- many features in common with the original design of
trol. GHR, but differs in the key respect that it uses a single
The most fundamental area of innovation is in the pass tube arrangement, unlike the original design
primary reforming area, where the recycling of heat which is a bayonet tube reformer.
from the secondary reformer effluent gas into primary The change to the AGHR design results in a
reforming completely alters the plant design, as well reformer which is of lower cost, easier to operate, eas-
as the plant layout and operation. It changes funda- ier to fabricate, and allows scale-up to in excess of
Mixed feed
Preheater
Boiler
Heat
exchange
reformer Secondary
Syngas reformer
Oxidant
Heat
exchange
reformer Secondary
Syngas reformer
QUESTIONS
(1) We have 16 secondary reformers in our plant and tube materials in the GHR would be operating at
are considering the installation of gas heated reformers temperatures which would make them vulnerable
in parallel with the secondary reformers in an attempt to metal dusting corrosion. Synetix therefore
to improve capacity and conversion. We are interested undertook a prolonged materials testing program
to find out from Synetix how to overcome the preva- to identify a number of candidate materials which
lence of metal dusting. We would also like to find out were resistant to metal dusting. Since then, Synetix
more about the seals that have been designed by has gained over 10 years operating of GHRs using
Synetix on the bottom end of the tubes. the chosen metallurgy with no evidence of corro-
F. W. Farnell, Synetix : From the start of the sion of the tube materials. In terms of the AGHR
development of Gas Heated Reformer (GHR) tech- development and the novel sliding seals, we would,
nology in the early 1980s, Synetix realized that the of course, discuss further details of these on a one
to one basis with prospective clients.